Knocked-down chair

ABSTRACT

A chair which is shipped disassembled in a small size container and is assembled at destination. The chair has a separate back, arms and seat-leg unit. Optionally, it includes rocking chair runners. The back and arms have cleats fixed to their lower portions which provide a firm foundation and a flush surface to be rigidly fastened to the seat-leg unit. The chair is easily assembled with hand tools and is extremely stable.

United States atent [1 1 Ostrdff et al.

[ 5] Apr. 17, 1973 KNOCKED-DOWN CHAIR [75] Inventors: Benjamin Ostrofi; Melvin George Ostroff, both of Gardner, Mass.

[73] Assignee: Standard Chair of Gardner, Inc.

Gardner, Mass.

[22] Filed: Apr. 5, 1971 [21] Appl. No.: 131,264

[52] US. Cl. ..297/440, 297/416, 297/445, 206/46 FN [51 1 Int. Cl ..A47c 4/02, A47c 7/54 [58] Field of Search ..297/440, 414, 416, 297/445, 452, 378; 206/45 [56] References Cited UNITED STATES PATENTS 3,1 15,367 12/1963 Gariepy ..297/440 2,678,088 5/ 1954 Jamison, Jr ..297/416 FOREIGN PATENTS OR APPLICATIONS 237,159 10/1959 Australia ..297/440 Primary Examiner-Casmir A. Nunberg Attorney-Chittick, Pfund, Birch, Samuels & Gauthier ABSTRACT A chair which is shipped disassembled in a small size container and is assembled at destination. The chair has a separate back, arms and seat-leg unit. Optionally, it includes rocking chair runners. The back and arms have cleats fixed to their lower portions which provide a firm foundation and a flush surface to be rigidly fastened 'to the seat-leg unit. The chair is easily assembled with hand tools and is extremely stable.

, 6 Claim, 3Drawing Figures PATENTED l 1975 SHEET 1 [IF 2 Fig. 2.

INVENTORS BENJAMIN OSTROFF BY MELVIN GEORGE OSTROFF 9 C 2/ J v 49% ATTORNEYS PATENTED R 1 71975 3.727.981

sum 2 0r 2 I1\'\-'E.\"I'ORS BENJAMIN OSTROFF MELVIN GEORGE OSTROFF BY am, PM/ 5%, JW+ yum A'IIORNEYS KNOCKED-DOWN CHAIR BACKGROUND OF THE INVENTION This invention relates to furniture and more particularly to an easily assembled chair and a method of compactly packing the disassembled chair for shipping.

Most furniture today is shipped from the factory already assembled. However, the great disadvantage of shipping pre-assembled furniture is that the container must be quite large relative to the weight of the fumiture container therein. Because of this undesirable volume to weight ratio in shipping pre-assembled fumiture, the shipping costs are extremely high. In fact, in this era of ever-increasing transportation costs, it is not unusual for a piece of furniture to have a shipping cost higher than its manufacturing cost. In the past, chairs have been made as knock-down units to minimize shipping size. However, most such chairs have been unsatisfactory either because they still required a sizeable shipping container or because they were difficult to assemble after shipment or because they did not readily assemble into a sturdy, rigid chair.

It is an object of the present invention to provide an easily assembled chair which overcomes the disadvantages of these previously known chairs.

Another object of the present invention is to provide an easily assembled chair which can be packed in a shipping container in such a compact fashion that the volume to weight ratio is greatly reduced, thereby lowering shipping costs.

Another object of the present invention is to provide an easily assembled chair which is quick and simple to assemble either by the retailer or the retail customer using common hand tools.

Another object of the present invention is to provide an easily assembled chair which is very stable, rigid and sturdy when assembled.

BRIEF SUMMARY OF THE INVENTION The easily assembled chair of this invention is adapted to be shipped disassembled in a small carton. The chair parts are nested together and substantially fill the carton, thereby efficiently utilizing it with a low volume to weight ratio. The chair is either assembled at the retail store or in the customers home. Not only are shipping costs reduced, but damage during shipment is practically eliminated because of the compact package of disassembled parts.

An important feature of this invention is the provision of cleats fixed to the lower ends of the chair back spindles and chair arm spindles. These cleats rigidly fix the spindles in position relative to each other and also form mounting platforms or bearing surfaces by which the back and arms are bolted to the seat. The cleats are flat and abut each other, end to-end, as they extend around the periphery of the seat.

A combination of through-bolting and bolting into threaded press-fit bushings is used to rigidly assemble the chair after it arrives at its destination.

Other objects and advantages of this invention will be described in more detail hereinafter. The invention comprises the chair construction itself, its combination of elements and arrangement of parts. The invention also comprises the method of packing the disassembled chair in a container for shipping. For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view in exploded perspective of the parts of the chair of the present invention;

FIG. 2 is a view of the chair of FIG. 1 shown knocked down and packed in a shipping carton; and

FIG. 3 is a view of the chair of FIG. 1 shown fully assembled with the cushions in place.

DETAILED DESCRIPTION-OF THE INVENTION In the drawings, FIG. 3 shows a completely assembled rocking chair 10 which is the preferred embodiment of this invention. However, it will be understood that the unique features of this invention can also be employed in other types of chairs.

FIG. 1 shows an exploded view of chair 10 clearly illustrating the mating parts thereof. Chair 10 has a combination seat-leg unit 12 which is comprised of a wooden seat frame 14 which is open at its center. A simple wire spring suspension 16 is rigidly carried in the central seat frame opening and both the seat frame 14 and the spring suspension are covered with a cushioned fabric cover and skirt 18 which pads and hides the wire suspension 16. Frame 14, suspension 16 and fabric cover 18 together form a substantially flat seat portion.

Four legs 20 are fixed to and extend downwardly from seat frame 14. Preferably, legs 20 are canted outwardly and are rigidly fixed in position by front and rear cross bars 22 and 24, respectively. The flat seat portion and the legs and cross bars together form seat- Ieg unit 12.

Preferably, the chair of this invention takes the form of a rocking chair. In this configuration, a pair of curved rocking chair runners I 26 is provided and fastener holes 28 are formed therein in alignment with the lower ends of legs 20. Fasteners 30 are used to assembly runners 26 to legs 20. The detachable fasteners 30 may take several forms, e.g., wood screws or bolts adapted to cooperate with threaded bushings bushings which are press-fitted into the lower ends of the chair legs.

The chair 10 has a chair back 32 which comprises a back rest portion including ahorizontal head piece 34 and vertical spindles 36 fixed to and extending downwardly from the head piece. The back rest portion is fixed at its lower end to a flat cleat 38 which has recesses in its upper surface to accommodate the spindles 36. Flat cleat 38 has a configuration, when viewed from above, which closely approximates the configuration of the back and side margins of the flat seat portion of seat-leg unit 12. Thus, when it is positioned upon the flat seat portion, it is smoothly aligned therewith. Flat cleat 38 has a pair of fastener holes 40 formed entirely therethrough and a pair of fastener holes 42 bored partially therein and opening at the lower surface of cleat 38. Threaded bushings (not shown) are press-fitted into holes 42. 7

Corresponding holes are bored entirely through the frame 14 of seat-leg unit 12 and fasteners 44 are inserted through the top of cleat 38 as shown in FIG. 1 and are engaged by nuts which bear against the underside of frame 14. Unshown fasteners are inserted through the bottom of frame 14 are are engaged in the threaded bushings fixed in holes 42. Obviously, the type and number of fasteners used is optional and may be varied within the scope of this invention. However, it has been found in practice that the employment of fasteners as shown in these drawings results in a very rigid structure which is quickly and easily assembled with common hand tools.

Chair also has a pair of chair arms 46 each of which comprises an arm rest portion including a horizontal curved arm piece 48 and vertical spindles 50 fixed to and extending downwardly from the arm piece. Each arm rest portion is fixed at its lower end to a flat cleat 52 which has recesses in its upper surface to accommodate the spindles 50. The flat cleats 52 have a configuration such that they smoothly abut flat cleat 38 as well as the side margins of the flat seat portion of seat-leg unit 12.

In the same fashion as previously described relative to chair back 32, the chair arms 46 are mounted on the seat-leg unit 12 by means of aligned holes and fasteners. Preferably, there are. four holes and four fasteners for each chair arm. This opposed bolting arrangement is clearly shown in FIG. 1 and ensures a very secure mounting. An optional strength-increasing construction feature is the provision of recessed areas in seat frame 14 beneath cleats 52 so that cleats 52 are seated in seat frame 14 as well as being bolted thereto.

To greatly increase the rigidity of the chair, the trail--- ing ends 54 of arm pieces 48 are formed with a concave notch corresponding with the convex periphery of vertical spindles 36. Fastener holes 56 are provided through the two outside spindles 36 and, as shown in FIG. 1, fasteners 58 are inserted through holes 56 to engage arm pieces 48 and to draw them tightly against the two outside spindles 36. This arrangement provides the primary bracing for chair back 32 to support it 7 against the rearward pressure exerted by a seated occupant. Also, the chair arms 46 are rigidly braced against lateral sway.

FIG. 3 shows the installation of a seat cushion 60 and a back cushion 62. These removable cushions may be held' in place by tie strings, snaps or other conventional means.

FIG. 2 shows the compact package which the chair of this invention can assume for shipping purposes. A shipping carton 64 has side walls 66 and end walls 68. To pack the carton, the seat-leg unit 12 is first inserted so that its flat seat portion is flush against one carton side wall 66 and the four legs extend across the carton toward the opposite side wall 66. Preferably, cross bars 22 and 24 are disposed parallel to end walls 68.

' chair legs. Regardless, the chair can be packed in a carton no higher or wider than the chair back 32 and no deeper than the vertical dimension of seat-leg unit 12.

Of course, it is understood that each chair element would be wrapped in cushioned packing paper before insertion into carton 64 to prevent damage and the hardware placed in a parts bag.

Thus, a very small shipping carton 64 can be used to ship the knocked down chair of this invention at a greatly reduced transportation cost because of the decreased space required. Experience has shown that savings of approximately percent are possible between shipping an assembled rocking chair and shipping knocked down rocking chair 10. Furthermore, rocker 10 can be quickly and easily assembled at the destination using only simple hand tools to producean exceptionally rigid and comfortable rocking chair.

The above description obviously suggests many possible variations and modifications of this invention which would not depart from its spirit and scope. It should be understood, therefore, that the invention is not limited in its application to the details of structure specifically described or illustrated and that within the scope of the appended claims, it may be practiced otherwise than as specifically described or illustrated.

We claim:

1. A chair adapted to be shipped disassembled and then assembled at destination comprising, in combination:

a. a seat-leg unit including a substantially flat seat portion and four legs fixed to the underside of said seat portion and extending substantially normal thereto;

b. a chair back including a back rest portion and a flat cleat fixed to the lower extremity of said back rest portion and being disposed substantially normal thereto, said flat cleat having horizontal length and width dimensions exceeding those of said back rest portion lower extremity;

. two chair arms each including an arm rest portion and a flat cleat fixed to the lower extremity of said arm rest portion and being disposed substantially normal thereto, said flat cleat having horizontal length and width dimensions exceeding those of said arm rest portion lower extremity;

ing flat bottom surfaces, said seat portion having flat upper surfaces at its back and side margins, and said cleats and said seat portion all having aligned fastening means provided therein to facilitate the fastening of the bottom surfaces of said cleats directly upon and against the marginal upper surfaces of said seat portion, said fastened cleats cooperating with said seat portion to provide resistance against unwanted pivotal tipping of said back rest and said arm rests relative to said seat portion; and said arm rest portions and said back rest portion having complementary fastening means provided thereon at their points of mutual contact to rigidly fasten them together. 2. The chair of claim 1 further comprising a pair of curved rocking chair runners having fastener holes formed therein, the lower ends of said seat-leg unit legs having corresponding aligned fastener holes formed therein, and fasteners adapted to be inserted into the aligned holes to assemble said rocking chair runners to said four legs to produce a rocking chair.

. said chair back cleat and said chair arm cleats havarm rest portion has a fastener hole formed in its trailing end and the adjacent back rest portion has a corresponding fastener hole formed therein, whereby said arm rest portions are adapted to be fastened to said back rest portion to provide greatly increased rigidity in the assembled chair.

6. The chair of claim 1 further including detachable back and seat cushions adapted to be attached to said chair. 

1. A chair adapted to be shipped disAssembled and then assembled at destination comprising, in combination: a. a seat-leg unit including a substantially flat seat portion and four legs fixed to the underside of said seat portion and extending substantially normal thereto; b. a chair back including a back rest portion and a flat cleat fixed to the lower extremity of said back rest portion and being disposed substantially normal thereto, said flat cleat having horizontal length and width dimensions exceeding those of said back rest portion lower extremity; c. two chair arms each including an arm rest portion and a flat cleat fixed to the lower extremity of said arm rest portion and being disposed substantially normal thereto, said flat cleat having horizontal length and width dimensions exceeding those of said arm rest portion lower extremity; d. said chair back cleat and said chair arm cleats having flat bottom surfaces, said seat portion having flat upper surfaces at its back and side margins, and said cleats and said seat portion all having aligned fastening means provided therein to facilitate the fastening of the bottom surfaces of said cleats directly upon and against the marginal upper surfaces of said seat portion, said fastened cleats cooperating with said seat portion to provide resistance against unwanted pivotal tipping of said back rest and said arm rests relative to said seat portion; and e. said arm rest portions and said back rest portion having complementary fastening means provided thereon at their points of mutual contact to rigidly fasten them together.
 2. The chair of claim 1 further comprising a pair of curved rocking chair runners having fastener holes formed therein, the lower ends of said seat-leg unit legs having corresponding aligned fastener holes formed therein, and fasteners adapted to be inserted into the aligned holes to assemble said rocking chair runners to said four legs to produce a rocking chair.
 3. The chair of claim 1 wherein said cleats are shaped, sized and positioned to be smoothly aligned with the back and side margins of said flat seat portion, said cleats abutting each other end to end.
 4. The chair of claim 1 wherein each said chair arm arm rest portion has a concave notch formed in its trailing end adapted to engage and interlock with an adjacent convex surface of said back rest portion to provide greatly increased rigidity in the assembled chair.
 5. The chair of claim 1 wherein each said chair arm arm rest portion has a fastener hole formed in its trailing end and the adjacent back rest portion has a corresponding fastener hole formed therein, whereby said arm rest portions are adapted to be fastened to said back rest portion to provide greatly increased rigidity in the assembled chair.
 6. The chair of claim 1 further including detachable back and seat cushions adapted to be attached to said chair. 